Sequential Injection Hardware Installation Typical Example

Document Sample
Sequential Injection Hardware Installation Typical Example Powered By Docstoc
					                                                                            Technocarb Equipment (2004 Ltd.)
                                                                            4 - 30435 Progressive Way
                                                                            Abbotsford, BC, Canada V2T 6W3
                                                                            Tel: (604) 854-6264
                                                                            Fax: (604) 854-6802
                                                                            Web: www.technocarb.com




                            Sequential Injection


     Hardware Installation - Typical Example




Technocarb - Sequential Injection – Hardware Installation Typical Example Rev3
    1. Disconnect Battery Negative terminal.




    2. Remove the upper intake plenum as per OEM
       vehicle manufacturer service and repair
       instructions and cover the intake manifold to
       avoid any particle to enter into the engine.




    3. According to plenum design and shape, mark
       each intake runner approximately 1 3/4”
       above the base flange in the center of each
       runner.




    4. Utilizing a 5.2 mm twist drill bit, drill one hole into each of the 6 runners at
       suggested marked location. Then use a M6 x 1.0 threading tap, mill threads into
       each hole.
       Caution: Ensure you remove ALL debris from the plenum. Use compressed
       air or other cleaning methods



Technocarb Sequential Injection – Typical Hardware Installation Rev3                      2
    5. One at a time, apply permanent thread locking compound to
       the threaded portion of each fuel nozzle as illustrated. (LokTite
       Red or equivalent)



    6. Screw in and hand-tighten each nozzle into the
       threaded holes in the intake manifold. Then
       smoothly tighten each nozzle keeping in mind
       that most of modern plenum materials are
       thermoplastics. Excessive torque can ruin the
       thread. Ensure no debris gets into the plenum.




    7. Cut 1/4” ID LPG compatible hose into equal segment length to connect each
       injector nozzle to plenum inlet. Note: The hose will only be subjected to low
       pressure and to under hood engine temperatures.


    8. Install each 1/4” ID segment of the approved hose
       over each fuel nozzle at the plenum and to the
       corresponding injector barb port at the injector
       block. Hoses should be clamped according to
       your local regulations. Some countries require
       permanent compression hose clamps (Oetiker
       clamp type) as illustrated in this picture.




Technocarb Sequential Injection – Typical Hardware Installation Rev3                   3
    9. Install the LPG ECU.
       It should be installed on a
       rigid part of the vehicle body
       under the hood, far away
       from electromagnetic or
       radio frequency interference
       sources such as ignition coils,
       alternator, high voltage
       wires, etc. Ideally the ECU
       should be installed in a
       location that is not subjected
       to constant moisture.




    10. Pull back the lock mechanism on each of the ECU’s main wiring harness and
        connect the harness to the ECU as illustrated.

    Note: Note color matching on both harness connector and ECU receptacle.




    11. Re-install the intake plenum to the engine assembly as per OEM vehicle
        manufacturer service and repair instructions.




Technocarb Sequential Injection – Typical Hardware Installation Rev3                4
    12. Install the LPG injector rail(s) in a location that allows the rails to be mounted on
        a bracket attached to the intake manifold or valve covers.
        Looks and appearance are important but always observe the following rules:
    • The hoses from the reducer to the injector rails must be of equal lengths.
    • The hoses from the injector rails to the nozzles in the plenum must be of equal
        lengths.
    • The Injector rails must not be installed in serial but in parallel (See Picture Below)
    • Ensure the ability to be able to plug/unplug electrical connectors to the injectors.
    • Only one temperature sensor is installed at the end of the injector rail, even on
        systems using more than one injector rail like V6, V8 and V10 engines.
    • Connect and properly clamp a hose from the hose barb port available at the
        temperature sensor and join it to the pressure port barb at the MAP pressure
        sensor. Be careful to select the right port at the MAP Pressure Sensor, which has
        two ports, one for vacuum, one for pressure.

8 Cylinder Engine Layout




Technocarb Sequential Injection – Typical Hardware Installation Rev3                       5
    13. Number the plenum ports for each cylinder. Please note that this is an independent
        and individual numbering system without any relation to the engine spark plug
        firing order.
        The purpose of numbering the cylinders is to facilitate and ensure that the Petrol
        injector wiring will match the corresponding LPG injector wiring and hardware
        on each cylinder.
        Refer to the picture below and to the wiring and hardware schematics.




    14. Ensure there are no kinks or restrictions to any of the hoses
        connecting the propane injectors to the intake system of the
        engine.

    15. Fasten the pressure reducer to any solid part of the vehicle such
        as metal battery stand, fender, firewall, or any rigid frame
        under the hood. (Do not mount the reducer on the engine
        assembly).




Technocarb Sequential Injection – Typical Hardware Installation Rev3                    6
    16. Ensure accessibility to reducer to facilitate any future service requirements.
        The reducer must be installed vertically with the LPG outlet port pointing down.
        The reducer must be also mounted in such a way that the inlet port will be parallel
        to the vehicle inertial movement direction. (Rear to front).

    17. Installing the heat exchange coolant
        line to the reducer. Identify the
        upstream and downstream hot coolant
        lines in the heater system. Using two
        “Y” diverter fittings, divert two 5/8”
        hoses (in and out) to the pressure
        reducer heat exchanger chamber as
        illustrated below. Even though the
        coolant ports in the regulator are
        usually not marked as in or out, it is
        recommended that the IN port be on
        the bottom. See diagram below




    18. Pressure-test and purge the cooling system as per manufacturer’s instructions.

    19. Clean up any spilled coolant.




Technocarb Sequential Injection – Typical Hardware Installation Rev3                      7
    20. Install a vapor inline filter on each LPG hose between the pressure reducer and
        the injector rail as illustrated. Note: Follow the flow direction indicated on each
        filter.




    21. Connect the VACUUM line from the pressure reducer vacuum port and the
        vacuum port on the MAP pressure sensor, to a common vacuum port on the intake
        manifold or tee into a good engine vacuum line.



Technocarb Sequential Injection – Typical Hardware Installation Rev3                      8
    22. Connecting PW2 Level sender.
Attach PW2 sender to the tank on top of the designated magnetic signal surface and plug
in the white connector harness. Route the sender wire harness to the engine compartment.
Connect the three (White/Red/Black) wires as follows:

White Wire: Connect to the white wire from the LPG- ECU harness.
Red Wire:    Connect to a (+) 12V line live at Key On Engine Off. We suggest using
same (+) 12V wire from anyone Petrol injector.
Black Wire: Connect to Ground.




Technocarb Sequential Injection – Typical Hardware Installation Rev3                   9
Note: The housing of the LPG level sensor in your tank could have a larger diameter than
the supplied level sensor. You may use a supplement to make it fit in the case.

    23. Secure all hoses/wires etc. as required. Re-inspect the ENTIRE installation.




Technocarb Sequential Injection – Typical Hardware Installation Rev3                   10

				
DOCUMENT INFO